Al–Cu–Fe coatings manufactured by the flame spraying process

ABSTRACT

Two-hour milled (activated) Al–20Cu–15Fe (at%) powders were subjected to annealing at 600°C for 1 h. The phase and microstructural evolutions were characterized by X-ray diffractometry and scanning electron microscopy. Al₇Cu₂Fe and Al₆₀Cu₃₀Fe₁₀ phases were formed after annealing. Both annealed and milled powders were consolidated using the flame spraying process. In both cases, FeAl(Cu) was the major phase while some oxides and α-Fe(Al,Cu) were also found. The coating produced from the milled powder was severely cracked and showed higher oxide content. The coating prepared from the annealed powder showed better quality. It was annealed at 600°C for 1 h to investigate the thermal stability of the various phases. All phases persevered after annealing while the Fe₂Al₅ phase was formed as a new phase.

KEYWORDS:

• Al–Cu–Fe
• annealing
• characterization
• coating
• flame
• microstructure
• processing
• spraying